Midtronics INTELLECT EXP HD User manual

Midtronics Expandable

Electrical Diagnostic Platform

INSTRUCTION MANUAL

Battery Management Innovation

For testing 6- and 12-volt

heavy-duty, automotive,

and commercial batteries,

and 12-volt and 24-volt

charging systems.

Chapter 1: Before You Begin

For safe, efcient, and accurate testing, review the safety and operating instructions in this manual before

using the analyzer.

We also recommend that you register the analyzer to activate your warranty.

Safety Precautions

Inspect the battery for damages and check the electrolyte level. If the electrolyte level is too low, replenish

it and fully charge the battery.Always use the necessary safety precautions when working with batteries to

preventsevereinjuryordeath.Followallmanufacturers’instructionsandBCI(BatteryCouncilInternational)

safety recommendations, which include the following precautions:

•DANGER—RISK OF EXPLOSIVE GASES: Batteries can produce a highly explosive mix of

hydrogen gas and oxygen, even when the battery is not in operation. Always work in a well-

ventilated area. Never smoke or allow a spark or flame in the vicinity of a battery.

•WARNING—REQUIRED BY CALIFORNIA PROP. 65: Battery posts, terminals, and related

accessories contain lead and lead compounds, chemicals known to the state of California to

cause cancer and birth defects or other reproductive harm. Wash hands after handling.

•Battery acid is highly corrosive. If acid enters your eyes, immediately flush them thoroughly

with running cold water for at least 15 minutes and seek medical attention. If battery acid gets

on your skin or clothing, wash immediately with water and baking soda.

•Always wear proper safety glasses or face shield when working with or around batteries.

•Keep hair, hands, and clothing as well as the analyzer cords and cables away from moving

engine parts.

•Remove any jewelry or watches before you start servicing the battery.

•Use caution when working with metallic tools to prevent sparks or short circuits.

•Never lean over a battery when testing, charging, or jump starting it.

Chapter 1: Before You Begin

Chapter 2: Overview

The inTELLECT EXP-1000 HD tests 6- and 12-volt heavy-duty automotive and commercial batteries, and

12-volt and 24-volt charging systems. In addition to a standard single-battery test, the EXP has a test rou-

tine designed for multiple-battery vehicles and a specialized heavy-duty battery algorithm for larger batter-

ies. Other tools in the EXP include a digital multimeter with a scope, and a conductance cable drop test.

The large backlit graphical screen and icon-based user interface make diagnostics simple for the novice

and experienced electrical technician.An alphanumeric keypad with selection scrolling and soft (multifunc-

tion) keys make the EXP as easy to use as a remote control or cell phone. A memory card system allows

for upgrades, quick storage, and transfer of test data.

Case Layout

The EXP-1000 HD kit includes a hard-sided, molded carrying case. The

case holds all accessories, with

room for future options.

Printer batteries

Printer paper

Cable storage

Side-post

stud adapters

Printer charger

Group 31

stud adapters

IR printer

inTELLECT EXP

Battery

test cable

Amp clamp

Chapter 2: Overview

Standard and optional test cables include:

Heavy duty battery test cable

(15-foot)

Amp clamp

DMM (Digital Multimeter)

cable

Banana Jack adapter

and probes

Test Leads, Connections, and Data Ports

The top of the EXP has two connectors for test cables:

RJ45 connector (Accessories Port) with a

release lever for accessory test cable.

6-pin connector, with a locking ring, for the

battery test leads.

In addition, the top-left corner of the EXP has two IR data

ports:

Temperature measurement sensor.

Data transmitter, which transmits test results to

an IR printer

RJ456-pin

Chapter 2 : Overview

The bottom and right side of the EXP have two data ports:

DB-9 connector for future expandability.

Spring-loaded SD card slot for test data storage and software upgrades.

Connecting the Battery Test Cable

Connect the battery test cable to the EXP by rst aligning the cable connector’s 6 holes with the 6 pins on

top of the EXP. Firmly insert the connector and nger-tighten the locking ring.

Connecting an Accessory Cable

If you are using an accessory cable, plug it into the accessories port on top of the EXP as you would a

phone jack. To remove it, press the lever and pull out the cable connector.

Inserting an SD Card

The SD card slot contains a plastic ller card for protection. The EXP can store test results on an SD card.

To remove the ller card, push briey on its edge to release it and pull it from the slot.

When inserting an card, push it into the slot until it locks. The card is correctly inserted when it is not

protruding from the slot.

Chapter 2 : Overview

Display and Keypad

The analyzer keypad and display work together to help you quickly nd and use the right tools at the right

time. The display also keeps you on track with on-screen navigation aids, directions, and messages. The

illustration below shows how the elements on the screen relate to the keypad.

Status Indicator: EXP Internal Batteries

This indicator appears in the screen’s top left

corner. It lets you know the status and charge

level of the analyzer’s six 1.5 volt batteries.

The X in the indicator shows that the EXP is

ture which conserves the internal batteries.

Voltmeter

When you rst connect the analyzer to a bat-

tery it functions as a voltmeter. The voltage

reading appears above the left soft key until

you move to other menus or functions.

Soft Keys

Press the two Soft Keys linked to the bot-

tom of the screen to perform the functions

displayed above them. The functions change

depending on the menu or test process. So it

may be helpful to think of the words appear-

ing above them as part of the keys. Some

of the more common soft-key functions are

SELECT, BACK, and EXIT.

POWER Button

Press the POWER button to turn the analyzer

on and off. The analyzer also turns on auto-

matically when you connect its test leads to a

battery.

Title Bar

The Title Bar shows you the name of the cur-

rent menu, test tool, utility, or function.

Selection Area

The Selection Area below the Title Bar con-

tains items you select or into which you enter

information. The area also displays instruc-

tions and warnings.

Directional Arrows

When displayed in menu screens, the Direc-

tional Arrows show you which ARROW key

on the keypad to press to display other icons

or screens. The Up and Down Directional Ar-

rows, for example, let you know when to press

the UP and DOWN ARROW keys to display

the screens above and below the current

screen.

The Left and Right Directional Arrows tell you

when to use the LEFT or RIGHT ARROW

keys to select an icon.

Chapter 2: Overview

When displayed under a list of options, the

Directional Arrows show you which keypad

arrow to press to highlight a character or an

item in a list.

Scroll Bar

Another navigational aid is the Scroll Bar on

the right side of the screen. The position of

its scroll box shows you whether the screen

is the top (or only screen), middle, or last in a

series.

Keypad Arrows

While the Directional Arrows serve as road

signs, the KeypadArrows are the vehicle to its

functions and features. You use the keypad to

log on, navigate to menus and options, cus-

tomize settings, and perform tests.

Alphanumeric Keypad

In some cases, you can use theAlphanumeric

Keypad to enter numerical test parameters

instead of scrolling to them with the ARROW

keys.

Top

or only

screen

Middle

screen Last

screen

Scroll

Box

You also use the Alphanumeric Keys to cre-

ate and edit customer coupons and your shop

contact information on printed test results, and

manage technician IDs.

To add a space, press the RIGHT ARROW

key. To erase a space and insert a character,

press the LEFT ARROW key.

Refer to the table below for the characters as-

sociated with each alphanumeric key.

Chapter 2: Overview

Keypad Character Assignment

1 $ - ( ) 1

2a b c 2

3d e f 3

4g h i 4

5j k l 5

6 m n o 6

7p q r s 7

8t u v 8

9w x y z 9

0% , . # 0

Backspace

Space

Key Character

Data Entry Methods

To perform a particular test or function, the EXP will ask for different types of information. This means that

the methods you use to enter information will change depending on the type of information requested. The

four types of entry methods are described below.

Typically, the soft key below the left half of the screen cancels your choice or returns you to the previous

screen, although the command above it may vary. (Examples: BACK and PRINT.) In a similar fashion, the

soft key below the right half of the screen conrms your choice, although the word above it may also vary

(examples: SELECT and NEXT).

Menu icons

A menu icon is a graphical representation of a function you can select, such as the Diode Icon in

the DMM Menu. To select an icon, use the LEFT or RIGHT ARROW key to highlight it. Highlighting

changes the icon to a white picture on a black background. To conrm your selection, press the

appropriate soft key.

Option Buttons

Some lists have option buttons before each item. To select an item, use the UP/DOWN ARROW keys

to move the dot to the button next to the item. You can also use the alphanumeric keypad to enter the

number preceding the option button. To conrm your selection, press the appropriate soft key.

Scrolling Lists

Scrolling lists contain items that extend above and below the screen or the selection box that contains

them. To indicate that there are more items, the symbols appear to the right of the rst visible or

highlighted item on the list.

To select from the list, use the UP/DOWN ARROW keys to scroll to the item, or use the keypad to

enter your choice, and press the appropriate soft key. Scrolling increases and decreases the units by

ve. To increase your scrolling speed, hold the UP or DOWN ARROW key.

Chapter 2: Overview

Alphanumeric Entry

Some selections require you to use the alphanumeric keypad. These “user-dened” selections have

a blinking horizontal line (cursor) to the right of the last character.

Use the UP/DOWN ARROW keys to highlight a line for editing. Display the character, symbol, or

number you want by rapidly pressing its key as many times as needed. If you pause, the cursor

moves to the right. To backspace, press the LEFT ARROW key. Use the RIGHT ARROW key to add

a space. Use the UP/DOWN ARROW keys to highlight a line for editing. When nished, press the

appropriate soft key to save your settings.

Chapter 2: Overview

Menu Maps

This section will help you get to your destination while letting you know what test leads you may need when

you arrive. The test leads are represented by symbols for their connectors.

Main Menu

The Main Menu is the starting point for all tools and utilities, which are depicted as icons. Some icons

lead directly to the function they represent, while others are menu icons that lead to two or more

functions. Menu icons are marked here with an asterisk (

) and are mapped on the following pages.

Main Menu (Screen 1)

Main Menu (Screen 2)

Main Menu (Screen 3)

Tests one battery using

the battery information

you select in a series of

screens.

Tests the battery pack or

individual batteries (and

the starting and charging

systems.

Digital multimeter with

eight test meters, a tem-

perature sensor, and

options for clamps and

probes.

Includes a test counter,

data transfer utility, the

EXP software version

and serial number.

Allows you to view your

stored test results and

print them to an optional

IR printer.

Nine utilities, many of

which customize your

user interface.

Required test leads

Amp

clamp

Battery

test Cable

drop

Optional

Tests both sides of a

circuit simultaneously for

voltage drop. Three pre-

set tests and one user-

dened.

Clamps

only

Chapter 2: Overview

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